Why does the wire break?
Possible causes include excessive tension, aggressive feed, worn wire, poor joint quality, small wheel diameter, misalignment, sudden material load, or insufficient coolant.
Why are periodic marks visible on the cut?
Periodic marks may come from the loop joint, wheel vibration, coating inconsistency, or repeated path disturbance.
How should troubleshooting start?
Change only one variable at a time. Record speed, feed, tension, coolant, cut depth, wire condition, fixture setup, and surface result.
Application reference
For commercial equipment or test-cut planning, see Ensoll's contact Ensoll.